Construction of a 3D printing device for producing components

ABSTRACT

The invention relates to a device for producing three-dimensional models, comprising a coater, which includes an ejection opening, at least one print head, which is mounted on a print axis, the ejection opening of the coater being disposed toward the top in the coating direction, and the print head being disposed counter to the coating direction with the opposite orientation on the printing axis behind the coater in the coating direction; the invention also relates to a method for producing three-dimensional models.

CLAIM OF PRIORITY

This application is a divisional patent application of U.S. patent application Ser. No. 14/443,225 filed on May 15, 2015, which is a national phase filing under 35 USC § 371 from PCT Application serial number PCT/DE2013/000685 filed on Nov. 21, 2013, and claims priority therefrom. This application further claims priority from German Patent Application DE 10 2012 022 859.7 filed on Nov. 25, 2012. These applications (U.S. Ser. No. 14/443,225, PCT/DE2013/000685 and DE 10 2012 022 859.7) are each incorporated herein in its entirety by reference.

FIELD

The invention relates to a device as well as a method for constructing three-dimensional models in layers.

BACKGROUND

A method for producing three-dimensional models from computer data is described in the European patent specification EP 0 431 924 B1. A first material, a particulate material in this case, is applied in a thin layer onto a building platform, which, if necessary, is surrounded by a container, and a second material, which may form a solid with the first material, is subsequently applied thereupon. According to EP 0 431 924 B1, a particulate material is provided, for example, as the first material, and a binder material is then selectively printed onto the particulate material using a print head. The particle area onto which the binder is printed sticks together and solidifies under the influence of the binder and, if necessary, an additional hardener. The platform is then lowered by a distance of one layer thickness into a build cylinder and provided with a new layer of particulate material, which is also printed as described above. These steps are repeated until a desired height of the model is achieved. A three-dimensional model is thereby produced from the printed and solidified areas.

After it is completed, the model produced from solidified particulate material is embedded in loose particulate material and is subsequently removed therefrom.

Other powder-supported rapid prototyping processes work in a similar manner, for example selective laser sintering or electron beam sintering, in which a loose particulate material is also deposited in layers and selectively solidified with the aid of a controlled physical radiation source.

All these methods are referred to collectively below as “three-dimensional printing methods” or 3D printing methods.

Another method for constructing a layered body from loose particulate material is known from WO2011/127897A2. The build process takes place according to the “continuous 3D printing” principle and is another variant of the powder-processing 3D printing method.

SUMMARY

It is possible to produce continuous components, also referred to as molded parts, using an endless, horizontal layer feed.

In continuous 3D printing, the component length is almost unlimited.

In conventional systems, the components are produced in layers vertically from top to bottom. If the component size exceeds the building height predefined for the specific system, the component must be segmented and produced in multiple build processes. For this purpose, the finished components must be consecutively removed from the system and placed on each other to form an accurate fit and glued. In this case, the production of large components is limited in terms of size and productivity.

In continuous 3D printing, the layer feed takes place in the horizontal direction using a continuous conveyor belt. Since gravity prevents a layer from being applied perpendicularly to the layer feed, the individual layers are applied spatially at an angle to the perpendicular. The angle is selected in such a way that it is smaller than the specific angle of repose of the corresponding powder material.

The build plane abuts an enclosed conveyor line, whose length is adapted, e.g., to the method-dependent hardening duration. At the end of the conveyor line, the finished components enter a removal area or unpacking area. There, the components are freed of unbound powder material and removed without having to interrupt the production of additional parts. In the case of particularly long parts, this area may be expanded, e.g., with roller tracks.

However, the known devices and methods for building models, also referred to as molded parts, in layers, have construction-induced disadvantages which may result in inaccuracies or defects in the molded parts during their manufacture. In known devices and methods, for example, the coater is moved back over the coated plane after the coating operation. It is possible for particulate material to undesirably detach from the coater and fall onto the build plane (build space). Particulate material may thus come to rest in places where it is not intended to be. As a result, a collision between the print head and an accumulation of particulate material thus created may occur. This may damage both the print head and the build space and thus the components.

It is equally unfavorable when fluids enter the build space uncontrollably. They may damage the build space and thus the molded body to be produced and even render the produced molded parts unusable.

As a result, there has long been a need to avoid or at least reduce the aforementioned disadvantages of the prior art.

The object of the present invention is therefore to provide a device and a method which avoid or at least improve the disadvantages of the prior art and with which the method for producing molded parts may be carried out in an improved manner.

The object according to the invention is achieved by the device according to claim 1 and the method according to claim 9.

Preferred embodiments are implemented in the subclaims.

In particular, the invention relates to a device and a method for producing three-dimensional models or molded parts, the device being characterized by an advantageous arrangement of the function units. In particular, this construction in layers according to the invention is used in the inclined bed method of 3D printing.

DETAILED DESCRIPTION

The different aspects of the invention are illustrated in greater detail below.

In one aspect, the invention is a device for producing three-dimensional models, comprising a coater (1) which has an ejection opening, at least one print head (2), which is mounted on a print axis, the ejection opening of the coater being disposed at the top in the coating direction and the print head being disposed counter to the coating direction with the opposite orientation on the print axis behind the coater in the coating direction.

All known coaters may be used which are suitable for implementing the idea of the invention. The coater may be any coater which has a leveling element, or a means having the same function, counter to the coating direction. This prevents particulate material from being able to slide or fall down in the direction of the print head. Any embodiments may be used which push the particulate material to be applied upward, such as rollers, blades, lips, etc., and which prevent a described sliding of the particulate material.

The special arrangement of the print head and coater is particularly advantageous during operation of the system, since the print head and the coater may immediately approach the peripheral units after each operation. With this arrangement, a new layer of particulate material may furthermore be applied to the build space when the coater is lifted. In the sense of the invention, “lifting” means that the coater moves upward over the build space at an inclined angle with respect to the horizontal. This prevents the particulate material from being able to fall over the build space. When lowered, the print head may then print the areas which need to be solidified to produce the molded part. In the sense of the invention, “lowering” means that the print head moves downward counter to the coating direction at an inclined angle with respect to the horizontal and parallel to the build space. This prevents an undesirable deposition of particulate material on the build space, whereby the particle layer would become uneven and the print head could collide with deposits of this type.

The device according to the invention furthermore comprises a coater cleaning unit (3), a coater filling unit (4), a central particulate material supply unit (6), a conveyor belt (7), an inspection unit (10), a print head cleaning unit with a spitting station (11), a capping station (12), a drop barrier (13), a collecting hopper (14), a conveyor line for excess particulate material (15), a collecting hopper in the unpacking area (16) and/or one or multiple channels (19).

In one preferred embodiment, the units of the coater peripheral units, preferably the coater cleaning unit (3), the coater filling unit (4) and the central particulate material supply unit (6) are disposed at the top in the coating direction, particularly preferably behind the build space.

The units of the print head periphery, preferably an inspection unit (10), a print head cleaning unit with a spitting station (11) and a capping station (12) are preferably disposed at the bottom in the coating direction, particularly preferably below the build space.

With the aid of the device according to the invention, a central particulate material conveyor may be disposed above the build space for automatically constructing the start feedstock.

Collecting hoppers may furthermore be disposed below the device (system) for collecting excess particulate material. One collecting hopper is preferably disposed at the front below the build space for collecting the excess or falling particulate material. Another collecting hopper is preferably disposed below the unpacking area.

The collecting hoppers preferably empty downward toward a conveyor line, which further conveys the particulate material and is also disposed on the bottom of the machine. The particulate material collected in this manner may then be reused. A “collecting line” in the sense of the invention is any suitable means for transporting the particulate material collected in this manner in one direction, preferably into a recycling container. For example, a screw conveyor may be used.

The conveyor line preferably has a central conveyor section, which is used to empty the collecting hoppers on the front side of the device and the collecting hopper in the unpacking area.

In another aspect, the invention relates to a method for producing three-dimensional models, a device according to the invention being used according to one of the aspects described above. In one method according to the invention, a start feedstock may be constructed with the aid of the device. A “start feedstock” is necessary to facilitate a startup of the manufacturing process and to provide a start surface made of particulate material, on which the coating with particulate material and subsequent printing with the print head may take place.

In one preferred embodiment of the invention, a coater applies thin layers of a particulate material. For this purpose, it travels along a linear drive system.

The coater preferably comprises a hopper which includes a gap-like opening in the vicinity of the coating plane. The ejection gap of the coater then preferably points in the coating direction. Upon excitation of the coater, particulate material emerges from this gap onto the coating plane. Roller coaters or blade coaters or combinations thereof are suitable as coaters. In all types, it is advantageous if the layer application takes place in the direction of the ascending coating plane and not the other way round, since this makes it possible to prevent the particulate material situated in front of the coater from sliding over the coating plane. With this orientation of the coater according to the invention, it is advantageously achieved that the coating is very even and remains stable. This also avoids undesirable and disadvantageous interactions from occurring between material provided for the coating and excess material.

The print head, which is preferably mounted on an orthogonal linear system, passes over the build space in a rastering process. In the rastering process, a distinction is made between the direction in which a strip the width of the print head is generated (print axis) and the direction in which the print head is offset by one strip width (print head positioning axis). The print head preferably travels downward in a meandering pattern.

A conventional binder, which is adapted to the particulate material, is preferably used. Particulate material/binder combinations are generally known and therefore do not need to be named explicitly.

The print head may also be preferably replaced by a radiation source or another suitable means for an energy-rich supply of radiation. In this case, the remaining components of the device are adapted accordingly.

In the present invention, the print head is preferably positioned in the coating direction and printing takes place orthogonally thereto. The present invention is furthermore preferably characterized in that the print axis and the coater move on a common axis pair. This means that the print head positioning axis is simultaneously the coater axis. However, in another preferred embodiment, it is also possible for the coater and the print head positioning axis to move on separate axis pairs.

In the build process of the present invention, one layer of particulate material is first applied from bottom to top. The print head then passes over the build space in the rastering process from top to bottom, counter to the coating direction, and applies extremely fine droplets of binder. Alternatively a print head the same width as the build space may be mounted, which prints the entire build space in one pass. The printing operation would then take place during the travel of the print head-coater unit to the lower edge of the build space.

In the proposed device, the coater passes over the build space another time during the rastering travel of the print head without applying a layer. The print head then moves in front of the coater during the printing operation. If particulate material undesirably falls down, it cannot disturb the printing operation. According to the invention, it is thus advantageously achieved that the molded parts to be produced are of very high quality in terms of precision. In another preferred embodiment, the ejection opening of the coater is oriented in the coating direction, and the print axis is preferably situated behind the coater. The print head is thus disposed counter to the coating direction, i.e., in relation to the inclined build space, the coater is disposed toward the top in relation to the print axis and the print head, the ejection opening and the print head being essentially oriented in opposite directions. In this device arrangement according to the invention, the peripheral units for the print head, i.e., for example the inspection unit (10), the print head cleaning unit (11), the capping station (12) and the drop barrier (13), are disposed in the lower area of the device plane. These components are thus disposed in a manner that is easily accessible to the operator and is user-friendly.

The coater cleaning unit (3) and the coater filling unit (4) are preferably disposed at the top of the device, preferably in front of the build space.

This arrangement also has the advantage that, after each cycle of coating and printing, the coater and print head function units may be moved to the peripheral units for the purpose of checking their flawless operation. This increases the quality of the molded parts to be produced in a time-saving manner. It is provided to be able to individually control how often the coater or the print head is moved to the peripheral units during the printing operation. This may take place after each coating or printing operation or at longer intervals, e.g., after each second or fourth operation.

The peripheral units of the coater comprise all functions for keeping the coater intact during and between the build processes.

The peripheral units of the print head are preferably: cleaning station, capping station, drop barrier, spitting station, drop scales and inspection unit.

In the cleaning station, the nozzle plate on the bottom of the print head is actively cleaned from the bottom during a special pass, e.g., using a rotating sponge roller.

The capping station closes the nozzle plate on the bottom of the print head with the aid of an extendable stamp and thus protects it against contamination and drying out between the build processes.

The drop barrier actively checks the nozzle plate on the bottom of the print head for deposits, such as drops or foreign bodies, using a light barrier, and causes the print head to be cleaned, if needed.

The spitting station collects drops and vapors from the print head when the latter clears itself for internal cleaning.

The drop scales supply the corresponding information for modularizing the drop size.

The inspection unit is a special access point in the system, which enables the bottom of the print head to be inspected and test printouts to be run on paper.

All the peripheral units which support the function of the print head are mounted on the lower front of the device according to the invention, which may also be referred to as the system, and are thus easily accessible to the operator. The fluid supply may be advantageously disposed, due to the arrangement of the print head periphery in this location.

Damages in the fluid system, or fluids which must be replaced during operation, are thus guided downward and cannot be distributed over the build space and the machine drives. This prevents fluids of this type from damaging the build space or contaminating the print head or the coater. The feed line for supplying fluid may thus also be kept short.

The coater periphery comprises the coater filling unit and the coater cleaning unit. The coater filling unit is advantageously disposed above the upper edge of the build space.

The coater carries along a certain stock of particulate material during the build process. From time to time, the stock must be replenished with particulate material from the coater filling unit. During the build process, the bottom of the coater or the coater ejection gap may become so dirty over time that the coater is no longer able to apply flawless coats. At the same time, the ejection gap may be contaminated.

The device thus preferably comprises a coater cleaning station. It cleans the bottom of the coater, including the ejection gap, using a brush which passes over the coater perpendicularly to the coating direction.

Particulate material falls off the coater both during the filling operation of the coater and during the cleaning thereof.

With the aid of the device according to the invention, falling particulate material is advantageously prevented from reaching the build space.

Due to the arrangement of the coater periphery above the build space according to the invention, leftover powder falls onto the finished feedstock and is thus safely transported away.

The coater filling unit is preferably supplied with particulate material centrally via an ejection point above and behind the build space.

It is possible to automatically construct the start feedstock needed for the build process through this ejection point. As an alternative to the automatic construction of the start feedstock according to the invention, it would otherwise be necessary to insert blocks, inclined plates, or to apply the particulate material by hand, so that the start layer and subsequent layers may be applied at the prescribed angle.

Due to the central arrangement of the ejection point, the transport paths of the particulate material are kept short and may pass outside the system without problems.

By keeping the conveyor line short, both the fresh particulate material and the conveyor system are protected.

During the build process, particulate material accumulates on the side of the build space and beneath the build space during coating, as a result of the process, and must be disposed of.

In one preferred embodiment, this particulate material is collected in channels on the side of the build space, which are situated at a steeper angle than the build plane, to the extent that particulate material contained therein slides downward due to gravity. A central container is preferably situated below the build space, into which the two side channels empty, so that the leftover particulate material may be collected there. This container is particularly preferably provided with an opening along the lower build space edge, so that leftover particulate material may also be collected there, which is transported over the build space and into the container, e.g., with the aid of the coater.

The central container is preferably transported out of the system with the aid of a conveyor line, e.g., a conveyor spiral or a conveyor screw on the bottom of the system.

This conveyor line may also transport leftover particulate material which accumulates behind the system during the unpacking operation. Conveyor lines are thus reduced and the cleanliness of the build process is guaranteed.

One particularly preferred aspect of the invention is the combination of the central particulate material supply, which continuously fills the coater. The start feedstock may also be advantageously constructed hereby, so that a manual construction of the start feedstock, which was previously necessary, is dispensed with. This is a great advantage, among other things, with respect to time savings and the manageability of the method.

Another advantageous aspect of the invention is the mounting of a disposal system, which makes it possible not only to collect fallen particulate material and return it to the production process but also to supply the leftover particulate material from the unpacking as a whole to the recycling function in the method. Collecting hoppers are preferably mounted on the front side of the device, below the device and below the unpacking area, which are provided with a common conveyor line, which supplies the material to be recycled to a recycling container. The particulate material recovered in this manner is preferably subjected to treatment steps which remove process-induced contaminants therefrom. It is then fed back into the 3D printing process. A structure of this type is illustrated, for example, in FIG. 3.

The invention also relates to a method for producing three-dimensional models (molded bodies).

One particular advantage of the method according to the invention is that, during startup, the start feedstock does not have to be constructed by hand, but instead an automatic startup is possible, due to the special design of the device. Previously, it was necessary to build up the start feedstock by hand, so that the 3D process using the construction in layers could begin. The device and method according to the invention were able to overcome this disadvantage and thus provide a faster and more straightforward method.

Preferred embodiments are illustrated in the figures:

FIG. 1 shows the functional principle of the continuous 3D printing process. The left side shows the front side of the machine, including the build space on which the components are produced in layers. The application of the individual layers takes place at an angle which is smaller than the specific angle of repose of the processed particulate material. Conveyor belt (7) moves feedstock (8) to the right to the back of the machine. Finished components may be removed here.

FIG. 2 shows the preferred structure of the invention. Axis system (9), which positions the print head, is disposed to the left and right of build space (18) on the front side of the machine. Coater filling unit (4) and coater cleaning unit (3) are situated at the top behind the build space. Excess particulate material from the cleaning or filling operation of the coater fall onto the feedstock without problems.

Particulate material supply unit (6) is situated centrally behind the coater filling unit. The latter may either supply the coater filling unit (4) with particulate material or automatically produce the necessary start feedstock before the start of a job. The print head periphery is situated in an easily accessible location beneath the build space.

FIG. 3 shows the disposal paths of the excess particulate material. Channels (19), which collect excess particulate material from the build process and conduct it to the collecting hopper on front side (14), are situated to the left and right of build space (18). Conveyor line (15) runs along the bottom of the machine and empties collecting hopper (14). The conveyor line also empties collecting hoppers (16) from the unpacking area on the back of the machine.

LIST OF REFERENCE NUMERALS

1. Coater

2. Print head

3. Coater cleaning unit

4. Coater filling unit

5. Finished component

6. Central particulate material supply unit

7. Conveyor belt

8. Feedstock

9. Axis system

10. Inspection unit

11. Print head cleaning unit with spitting station

12. Capping station

13. Drop barrier

14. Collecting hopper, front side

15. Conveyor line, waste

16. Collecting hopper, unpacking area

17. Roller path of unpacking area

18. Build space

19. Channels 

What is claimed is:
 1. A method for producing three-dimensional models comprising steps of depositing a layer of a particulate material on an inclined surface of a feedstock using a device including a coater and a print head, wherein the coater deposits the particulate material only while moving in a coating direction up the inclined surface in advance of a print head; wherein the coater and the print head are mounted on a print axis, the coater has an ejection opening disposed toward the top of the feedstock in the coating direction and the print head prints on the deposited particulate material while traveling down the inclined surface in advance of the coater; wherein the feedstock includes a previously deposited layer of the particulate material.
 2. The method according to claim 1, wherein the method includes constructing a start feedstock including the particulate material and having the inclined surface using the device.
 3. The method of claim 1 comprising a step of cleaning the coater with a coater cleaning unit.
 4. The method of claim 3 comprising a step of filling the coater with a coater filling unit.
 5. The method of claim 4, comprising a step of moving the feedstock with a conveyor belt.
 6. The method of claim 4, comprising a step of filling the coater filling unit with particulate material from a central particulate material supply unit.
 7. The method of claim of claim 4, comprising a step of cleaning the print head with a spitting station.
 8. The method of claim 4, wherein the coater cleaning unit and the coater filling unit are disposed toward a top in the coating direction.
 9. The method of claim 7, wherein the coater cleaning unit and the coater filling unit are disposed toward a top in the coating direction.
 10. The method of claim 7, wherein the spitting station is disposed toward a bottom in the coating direction, particularly preferably below the build space.
 11. The method of claim 9, wherein the spitting station is disposed toward a bottom in the printing direction.
 12. The method of claim 11, wherein the method of includes a step of capping the print head in a capping station disposed toward the bottom.
 13. The method of claim 1, wherein the method includes collecting excess of the particulate material using a conveyor line.
 14. The method of 13, wherein the excess particulate material is collected in a collecting hopper.
 15. The method of claim 14, wherein the collecting hopper is disposed at the front below the build space.
 16. The method of claim 1, wherein the print head is mounted on a print head positioning axis that travels on an inclined print axis; and the coater is mounted on a coater axis orthogonal to the inclined print axis, wherein the coater and the print head independently move up and down the inclined print axis.
 17. The method of claim 16, wherein the print head includes a single print head.
 18. The method of claim 16, wherein the print head has a width that is about the same as a width of the build surface.
 19. The method of claim 16, wherein the print head moves in a meandering path including traveling along the print head positioning axis.
 20. The method of claim 1, wherein the method includes a step of depositing a start layer on a block or an inclined plate at a prescribed angle. 